Method and system for improving pump efficiency and productivity under power disturbance conditions

ABSTRACT

A system for controlling operation of a progressing cavity pump to maintain the motor operating under power disturbance conditions. For a blackout condition, a backspin controller uses regenerative power to provide controlled deceleration of the pump, counteracting backspin and preventing backspinning freely. For a brownout condition, a power dip controller weakens the motor field to maximize pump production consistent with reduced input power availability. For a phase loss or voltage imbalance condition, a phase loss controller reduces motor power output to keep drive system output power at or below single phase capacity.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority of provisional application Ser. No.60/581,282, which is entitled “Method and System for Improving PumpEfficiency and Productivity under Power Outage Conditions”, which wasfiled on Jun. 18, 2004, provisional application Ser. No. 60/668,016,which is entitled “Method and System for Improving Pump Efficiency andProductivity under Power Outage Conditions”, which was filed on Apr. 4,2005, provisional application Ser. No. 60/668,316, which is entitled“Method and System for Improving Pump Efficiency and Productivity underPower Outage Conditions”, which was filed on Apr. 5, 2005, andprovisional application Ser. No. 60/670,401, which is entitled “Methodand System for Improving Pump Efficiency and Productivity under PowerDisturbance Conditions”, which was filed on Apr. 12, 2005, the entiretyof these applications hereby being incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to pumping systems used in theproduction of oil and other liquids, for example, and more particularly,to a method and system for improving the efficiency and productivity ofprogressing cavity and electrical submersible pumps under powerdisturbance conditions.

Disturbances in the electrical power to variable speed drives operatingprogressing cavity pumps (PCP) and electrical submersible pumps (ESP)can cause significant safety, reliability, and production problems. Forexample, during normal pumping operation, a PCP provides significantamounts of energy to wind up the rod string, lift fluid to the surface,and lower the casing fluid level. During a power outage condition, thepump and its associated drive system lose the ability to control theenergy stored in the system. Wound-in rod string torque and fluid loadon the pump can cause the pump to backspin when power to the motor iscut off. An uncontrolled backspin can reach speeds that are many timesthe rated speed of the system. Completely uncontrolled backspin can alsocreate excess speed that is unsafe to personnel and or damaging to therod string or other equipment.

Loss of control of a PCP due to power disturbances causes the pump tobackspin which drains fluid from the production tubing. Backspin timescan last from minutes to hours depending on the specifics of the pumpapplication. Deep wells will generally have longer backspin times thanshallow wells or wells operating with high casing fluid levels.

The actual loss of production time could be more than twice the backspintime since fluid drained from the tubing and must be pumped back to thesurface. Frequent power disturbances can significantly diminishproductive capacity. Completely uncontrolled backspin can also createexcess speed that is unsafe to personnel and/or damaging to equipment.

There are four power disturbance conditions that can cause the pumpdrive to fault out and leave the pump spinning backward. The four poweroutage conditions are: 1) a power loss or blackout condition, in whichthe power may go out completely, 2) a power dip or brownout condition inwhich the incoming voltage may be present but at reduced voltage level,3) a phase loss condition in which the incoming three phase voltage maybe reduced to single phase, and 4) a voltage imbalance condition inwhich the incoming three phase voltages are out of balance.

There are several drive innovations that can be used to improve safety,reliability, and production during power disturbances. Mechanical,electrical, and hydraulic braking systems have been added to PCP driveheads to prevent injury to personnel as well as damage to the rod stringor other equipment. Backspin detectors have also been used in PCP andESP applications to prevent restarting of the pumps until all storedenergy has been exhausted from the system. These protective systems mustbe properly set up and maintained for reliable operation. Even so, thereis a finite chance that PCP drive head braking mechanisms can fail tooperate correctly during a backspin. Unsafe operation can be caused byincorrect set up, improper maintenance, or system component failure, forexample.

Moreover, starting into a backspinning pump can cause erratic torquethat damages the PCP rod string or the ESP motor and/or pump. Restartdelays have been introduced to prevent this type of starting and itsassociated potential for pumping system damage. PCP and ESP drivesystems can include a restart timer that delays pump operation after apower outage to ensure that the pump drive does not start into abackspinning load when power is restored. Restart delays allow energystored in rod windup and fluid levels to dissipate before restarting thepump. Unfortunately, the restart delays that are required may be up toseveral hours on deep wells. Frequent power outages combined with longrestart delays can significantly reduce production.

The restart delay should be no longer than necessary for the motor speedand torque to have diminished to zero. Known methods of setting therestart delay can result in arbitrarily long delays, which sacrificesproduction, or can be result in excessively short delays, which risksdamage to the pumping system.

FIG. 26 shows typical parameters for a PCP installation including poweroutage information, pump backspin speed, pump restart delay, pumpacceleration time and power outage time. FIG. 27 shows the behavior ofcasing and tubing flows and levels during a power outage event. The lossin production from a single power outage event using a backspin delaytimer can be significant (36.3%) for a deep well such as shown in thisexample.

It is accordingly the primary objective of the present invention that itprovide a method and system for improving the efficiency andproductivity of progressing cavity and electrical submersible pumpsunder power disturbance conditions.

It is another objective of the present invention that it maintaincontrol of a progressing cavity or electrical submersible pump operatingduring a power disturbance, including blackout, brownout, phase loss andvoltage imbalance conditions.

It is another objective of the present invention that it maintaincontrol of a progressing cavity or electrical submersible pump operatingduring a power loss condition by using the regenerated energy producedas the result of fluid load on the pump.

A further objective of the present invention is that it provide acontroller that provides controlled deceleration of a pump following apower disturbance condition to counteract backspin energy and to preventthe pump from backspinning freely.

The system of the present invention must also be of construction whichis both durable and long lasting, and it should also require little orno maintenance to be provided by the user throughout its operatinglifetime. In order to enhance the market appeal of the apparatus of thepresent invention, it should also be of inexpensive construction tothereby afford it the broadest possible market. Finally, it is also anobjective that all of the aforesaid advantages and objectives beachieved without incurring any substantial relative disadvantage.

SUMMARY OF THE INVENTION

The disadvantages and limitations of the background art discussed aboveare overcome by the present invention. With this invention, there isprovided a pump drive for a progressing cavity or electrical submersiblepump that maintains pump operation under power disturbance conditions.

The present invention maintains a pump running as fast as possible inspite of any power disturbance condition to maximize productivity andefficiency. Blackout conditions are addressed by a backspin controllerprovided by the present invention. Brownout conditions are addressed bya power dip controller provided by the present invention. Phase loss andvoltage imbalance conditions are addressed by the phase loss controllerprovided by the present invention. This invention will keep the driverunning using the power dip controller and the phase loss controllerunder a brownout condition or phase loss or voltage imbalance condition,respectively. If the bus voltage looks like it will fall below thevoltage that the drive needs to sustain control of the pump, thebackspin controller is enabled to use the energy in the fluid column tokeep the drive running, possibly until power is restored.

In accordance with the invention, there is provided a method forcontrolling the operation of a pump that is driven by an electric motordriven by a variable speed drive to maintain the motor operating in theevent of a power disturbance. The method comprises the steps ofdetermining the occurrence of an electrical power disturbance anddetermining whether the power disturbance is a blackout condition, abrownout condition or a phase loss or voltage imbalance condition. Abackspin controller provides controlled operation of the motor when thepower disturbance is determined to be a blackout condition. A power dipcontroller provides controlled operation of the motor when the powerdisturbance is determined to be a brownout condition, and a phase losscontroller provides controlled operation of the motor when the powerdisturbance is determined to be a phase loss or voltage imbalancecondition.

The backspin controller maintains the drive power for at least a portionof the duration of the electrical power disturbance by controlling thedrive to be in a power regenerative condition using the potential andkinetic energy of the motor and fluid column above the pump as theenergy source. Maintaining power during the portion of the electricalpower disturbance includes sensing operating parameters related to themotor and using the sensed values of the operating parameters incontrolling the motor during the power disturbance.

In accordance with the invention, upon detection of a power outage,regenerative power produced as the result of slow reverse speed appliedto the motor combined with fluid load on the pump is used to maintaincontrol of the operation of the pump. This includes providing controlleddeceleration of the pump in response to the detection of the electricalpower disturbance by commanding a negative torque and comparing thevelocity of the pump motor with a reverse velocity setpoint during thecontrolled deceleration.

In accordance with one aspect of the invention there is provided a pumpcontrol system including a backspin controller that responds to ablackout condition to provide controlled deceleration of the pump inresponse to the detection of the electrical power outage by commanding anegative torque. The backspin controller uses regenerative powerresulting from the fluid load on the pump to maintain control of theoperation of the pump during the power outage condition. In addition,the pump control system can include a shunt regulator or dynamic brakecontroller that allows backspin reverse velocity to be set high enoughto prevent undervoltage conditions and regulates the bus voltage toprevent overvoltage conditions that could otherwise affect efficientpump operation.

In one embodiment, the backspin controller compares the bus voltage witha setpoint value and transfers pump control operations from a normal runmode to a regenerative mode whenever the bus voltage decreases below thesetpoint value, indicative of a power outage. The backspin controllerresponds to the power outage to provide controlled deceleration of themotor in response by commanding a negative torque. The backspincontroller uses regenerative power resulting from the fluid load on thepump motor to maintain control of the pump during the power outagecondition. During deceleration when the reverse velocity setpoint isexceeded, the backspin controller maintains the motor and pump operatingat a controlled reverse velocity to allow regenerative charging of thedrive bus. This causes the fluid column in the tubing to slowly descendback into the well casing.

In addition, the efficiency and productivity of the pump are improvedbecause the pump can be restarted as soon as power is restored. Thefluid column does not have to be lowered fully and pumped back up to thesurface if the power returns before the lowering of the fluid column iscompleted. Accordingly, it is not necessary to provide a restart delaywhich, in prior art pump control systems, can result in arbitrarily longdelays which sacrifice production. Frequent power disturbances combinedwith long restart delays can significantly penalize production as isknown.

In accordance with another aspect of the invention there is provided apump control system including a power dip controller that responds to abrownout condition to provide controlled operation of the motor byweakening the motor field current and flux as the bus voltage decreasesduring the brownout condition.

In accordance with yet another aspect of the invention there is provideda pump control system including a phase loss controller that responds toa phase loss or voltage imbalance condition to provide controlledoperation of the motor by reducing the motor power output, if required,to maintain the single phase power capacity or voltage imbalancecapacity of the drive.

The system of the present invention is of a construction which is bothdurable and long lasting, and which will require little or nomaintenance to be provided by the user throughout its operatinglifetime. The apparatus of the present invention is also of inexpensiveconstruction to enhance its market appeal and to thereby afford it thebroadest possible market. Finally, all of the aforesaid advantages andobjectives are achieved without incurring any substantial relativedisadvantage.

DESCRIPTION OF THE DRAWINGS

These and other advantages of the present invention are best understoodwith reference to the drawings, in which:

FIG. 1 is a simplified representation of a well including a progressingcavity pump, the operation of which is controlled by a pump controlsystem incorporating a backspin controller, a power dip controller and aphase loss controller in accordance with the present invention;

FIG. 2 is a block diagram of the progressing cavity pump control systemof FIG. 1 including the backspin controller, the power dip controllerand the phase loss controller;

FIG. 3 is a state diagram for the backspin controller of FIG. 2;

FIG. 4 is a block diagram of the backspin controller of FIG. 2 providedby the present invention;

FIG. 5 illustrates waveforms obtained by a laboratory dynamometerexperiment of the backspin controller;

FIGS. 6, 7, 8 and 9 illustrate waveforms obtained by a laboratorydynamometer experiments of the backspin controller for different motorspeeds and torques, with FIG. 7 showing results obtained using abackspin controller with a dynamic brake controller in accordance withthe invention;

FIG. 10 is a graph of bus voltage (vdc—on the left side andVrms—corresponding to 3-phase line voltage on the right side) as afunction of speed;

FIG. 11 is a process flow chart for the power dip controller of FIG. 2provided by the present invention;

FIG. 12 illustrates waveforms obtained by a laboratory dynamometerexperiment of the power dip controller for a progressing cavity pumpoperating under constant torque conditions;

FIGS. 13-15 (and 16 and 17) illustrate waveforms obtained by alaboratory dynamometer experiment of the power dip controller for aprogressing cavity pump operating under various speed and torqueconditions;

FIG. 18 is a graph of ripple current as a function of % power applied tothe motor;

FIG. 19 is a block diagram of the phase loss controller of FIG. 2provided by the present invention;

FIGS. 20-22 (and 23 and 24) illustrate waveforms obtained by alaboratory dynamometer experiment of the phase loss controller for aprogressing cavity pump operating under various speed and torqueconditions;

FIG. 25 is a table illustrating power disturbance losses for variouscontrol techniques and operating conditions;

FIG. 26 is a table of typical parameters for a PCP installationincluding power outage information; and

FIG. 27 is a chart illustrating the behavior of casing and tubing flowsand levels during a power outage event.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The method and system of the present invention control the operation ofa pump that is controlled by a variable speed drive operating by anelectric motor to maintain the motor operation during electrical powerdisturbances. When the occurrence of an electrical power disturbance isdetected, the drive operates the motor at reduced capacity for sags ininput voltage, the loss of an in-coming phase, or an imbalance in supplyvoltages and power is maintained for at least a portion of the durationof the electrical power outage using regenerative electrical powerproduced as the result of a reverse drive applied to the motor due tothe fluid load on the pump.

As stated above, there are four power disturbance conditions that cancause the pump drive to fault out and leave the pump spinning backward.Blackout conditions are addressed by a backspin controller 60 (FIG. 2)provided by the present invention. Brownout conditions are addressed bya power dip controller 100 (FIG. 2) provided by the present invention.Phase loss and voltage imbalance conditions are addressed by the phaseloss controller 140 (FIG. 2) provided by the present invention. Whilethe pump control system is described herein as including a backspincontroller, a power dip controller and a phase loss controller,alternatively the pump control system can include only a backspincontroller, or a power dip controller or a phase loss controller, or thepump control system can include any combination of these controllersdepending upon the application of the pump control system. Also,setpoints can be established for parameters, such as bus voltage, toallow only either the backspin controller, power dip controller, orphase loss controller to operate for a preselected range of values forthe parameters, with suitable transitioning being provided in accordancewith changes in the parameter values.

The method and system of the invention are described with reference tothe control of the operation of a pump that is driven by an electricmotor by a variable speed drive to substantially eliminate the effectsof backspin in the event of a power outage. The system includes abackspin controller that is maintained during power outages to seizecontrol of the motor, providing controlled operation of the pump tocounteract backspin and prevent the pump from backspinning freely.

The backspin controller can be used to control progressing cavity orelectrical submersible pumps and to maintain control of the operation ofthe pumps during electrical power outage conditions, thereby providingimproved operating efficiency and productivity for the pump. Thebackspin controller maintains control of the operation of the PCP or ESPpump during power outages, counteracting backspin, preventing the pumpfrom freely backspinning, and allowing the pump to be restarted quicklyupon restoration of electrical power. For purposes of description of theinvention, the backspin controller is described with reference to anapplication for controlling a PCP pump. However, the backspin controlleralso can be used to control the operation of ESP type pumps.

Referring to FIG. 1, there is shown a block diagram of a pump controlsystem incorporating a pump backspin controller provided by the presentinvention. The present invention is described with reference to an oilwell 40 wherein oil is to be separated from an underground formation 22.The well includes an outer well casing 15 and an inner production tubing14 that extend from ground level to as much as 1000 feet or more belowground level. The casing 15 has perforations 26 to allow the fluid inthe underground formation to enter the well bore. It is to be understoodthat water can be combined with oil and the pump can be used for otherliquids. The control apparatus can also be used for water only.

A progressing cavity pump (PCP) 32 is mounted at the lower end of thetubing 14 and includes a helix type of pump member 34 mounted inside apump housing. The pump member is attached to and driven by a pump rodstring 35 which extends upwardly through the tubing and is rotated by amotor 36 in a conventional well head assembly 38 above ground level. Thetubing 14 has a liquid outlet 41 at the upper end above ground level 16.These elements are shown schematically in FIG. 1. The construction andoperation of the progressing cavity pump is conventional.

The operation of the pump 32 is controlled by a pump control system andmethod including a parameter estimator which can be similar to theparameter estimator disclosed in U.S. application Ser. No. 10/655,778which was filed on Sep. 5, 2003 and published as publication numberUS-2004-0062658 A1, and which is incorporated herein by reference. Thepumping system includes an electric drive 37 and motor 36 that rotatesthe rod string 35 that includes helix portion 34 of the pump 32. The rodstring 35 is suspended from the well head assembly 38 for rotating thehelix 34 that is disposed near the bottom 30 of the well.

The rod string 35 is driven by an electric motor 36, the shaft of whichcan be coupled to the rod string through a gearbox 17 or similar speedreduction mechanism. The motor 36 can be a three-phase AC inductionmotor designed to be operated from line voltages in the range of 230 VACto 690 VAC and developing 5 to 250 horsepower, depending upon thecapacity and depth of the pump. Electrical power for the electric drivesystem 37 as well as for a system controller 50 is obtained from asystem DC voltage bus 44 which is derived by rectification of theincoming AC power from a utility or a generator. The drive system 37includes an inverter for converting DC from the system voltage bus 44 to3-phase AC for driving the motor 36. The gearbox 17 converts motortorque and speed input to a suitable torque and speed output for drivingthe rod string 35 and helix 34 carried thereby. As is known, as the PCPis driven in normal operation, the fluid column stores potential energydue to the drive operation of the pump with the rod string moving fluidupwards. Power is equal to the product of torque and speed. The pumpmotor drive system can be controlled in a regenerative condition bycommanding a negative motor torque when motor speed is positive or apositive motor torque when motor speed is negative.

Pump Control System

Referring to FIG. 2, there is shown a simplified representation of thepump control system 20 for the pump 32. In one embodiment, signals forcontrolling the operation of the pump 32 are derived from values ofmotor speed and torque estimates as disclosed in detail in theabove-referenced publication number US-2004-0062658 A1. The controlsignals are produced using measured values of instantaneous motorcurrents and voltages, together with pump and system parameters, withoutrequiring down hole sensors, echo meters, flow sensors, etc. Thisself-sensing control arrangement provides nearly instantaneous estimatesof motor velocity and torque, which can be used for both monitoring andreal-time, closed-loop control of the pump. For example, in oneembodiment, instantaneous estimates of motor velocity and torque areprovided at the rate of about 1000 times per second. However, thebackspin controller provided by the present invention can be used inother pump control systems, including known pump control systems of thetype that employ down hole sensors, motor speed encoders, echo meters,flow sensors, etc.

A 3-phase AC line voltage is supplied to a power input circuit of thepump control system from a 3-phase AC power source 43. Typically, thepower input circuit is a bridge rectifier 45 that converts the AC powerto unregulated DC bus voltage 44. Phase shift transformers can be usedwith additional rectifier sections to reduce AC line harmonic currents.The DC voltage bus 44 uses capacitors 47 for voltage smoothing andenergy storage. An inductor 46 may be included to help smooth thecurrent flow to the bus capacitors 47.

Optionally, the pump control system 20 can include a shunt regulator ordynamic brake controller 57, shown in FIG. 2, to prevent overvoltagefaults. The dynamic brake controller 57 can be of conventional design,for example. By way of a non-limiting example, the dynamic brakecontroller 57 can include a switching device that is operable to connectan energy dissipating device to the bus capacitors 47 and associatedcircuitry in response to an overvoltage condition. The switching devicecan be a solid state switching device, such as a switching transistor, acontrolled rectifier and the like. The energy dissipation device can beformed by one or more dynamic braking resistors.

The dynamic brake controller 57 responds to changes in bus voltage, withan overvoltage condition causing energy stored by the bus capacitors 47to be dissipated. For example, when the bus voltage exceeds a setpointor “turn on” value for the switching transistor, the bus voltage cancause the switching transistor to be turned on, connecting the dynamicbraking resistor across the capacitors to allow the bus capacitors tobegin to discharge, thereby reducing the bus voltage by dumping energyinto the dynamic braking resistor. When the bus voltage is reduced to a“turn off” value for the switching transistor, the switching transistoris turned off, disconnecting the dynamic braking resistor from the buscapacitors to disable the voltage regulating function being provided bythe dynamic brake controller. The dynamic brake controller option makesthe backspin controller more 60 robust since the initial speed inreverse can be set higher without fear of an over voltage fault.

Variable speed drives rectify the AC line voltage into a DC bus voltagethat is converted by output switching devices into the variablefrequency voltage used to control the motor. The DC bus voltage isapplied to bus capacitors 47 that store electrical input energy fortransfer to the output. The energy stored in the bus capacitors 47 is afunction of their capacitance and the square of the applied voltage.Normal bus capacitors 47 will provide enough energy storage to ridethrough power outages of about 0.05 seconds.

The pump control system 20 includes transducers, such as motor currentand motor voltage sensors, to sense dynamic variables associated withmotor load and velocity. The pump control system further includes thesystem controller 50. Current sensors 51 of interface devices arecoupled to a sufficient number of the motor windings—two in the case ofa three phase AC motor. Voltage sensors 52 are connected across themotor winding inputs. A voltage sensor 53 is connected to the DC voltagebus 44. The motor current, motor voltage and bus voltage signalsproduced by the sensors 51, 52 and 53 are supplied to a processing unit54 of the system controller 50 through analog to digital (A/D)converters 56. The system controller 50 further includes a storage unit55 including storage devices which store programs and data files used incalculating operating parameters and producing control signals forcontrolling the operation of the pump system. The calculation data arestored in a memory 57. The stored programs include software implementingthe backspin controller 60, the power dip controller 100 and the phaseloss controller 140 provided by the present invention.

Motor currents and voltages are sensed to determine the instantaneouselectric power drawn from the power source by the electric motoroperating the pump. As the rod string 35 (FIG. 1) that drives theprogressing cavity pump 32 is rotated, the motor 36 is loaded. Bymonitoring the motor current and voltage, the calculated torque andspeed produced by the motor are used to calculate estimates of fluidflow and head pressure produced by the pump.

More specifically, the interface devices include devices for interfacingthe system controller 50 with the outside world. Sensors in blocks 51,52 and 53 can include hardware circuits which convert and calibrate themotor current, motor voltage, and bus voltage signals. After scaling andtranslation, the outputs of the voltage and current sensors can bedigitized by analog to digital converters in block 56. The processingunit 54 combines the scaled signals with motor equivalent circuitparameters stored in the storage unit 55 to produce a precisecalculation of motor torque, motor velocity, and bus power flow.

Backspin Control

In practice, the backspin control is constrained by a minimum andmaximum DC bus voltage, torque limits and control loop bandwidth. Theweight of the fluid column and the pump characteristics determine theload torque on the motor. This then, along with the losses in the pumpdrive system, determines the reverse velocity required to keep the driveoperating during power outage conditions in which utility voltage is notsufficiently adequate to power the voltage bus 44. Since regeneratedpower and system losses both tend to move in unison with torque, therequired reverse velocity is relatively constant and can be estimatedfrom known system parameters.

State Machine

FIG. 3 illustrates a finite state machine for the backspin controller 60shown in FIG. 2. For the sake of clarity, positive torque and speed onthe motor, rod and pump rotor are defined to be in the direction thatproduces fluid up the tubing 14 (FIG. 1). Negative torques and speedsare in the opposite direction. Also, by way of illustration, FIG. 5shows waveforms obtained by a laboratory dynamometer experiment of thebackspin controller 60. FIG. 5, line A shows torque, FIG. 5, line Bshows the bus voltage and FIG. 5, line C shows velocity.

Referring to FIGS. 1 and 3, the backspin controller 60 responds to apower outage and, taking advantage of the reverse drive applied to themotor 36 due to the fluid load on the pump 32, uses the regeneratedelectrical power produced by the motor 36 to maintain the pump drivesystem (including the backspin controller 60) in an operational state.The pump drive system causes the rod string 35 to be rotated in thereverse direction, but at a controlled speed determined by the backspincontroller 60. In this way, free backspin is prevented and control ofthe operation of the pump 32 is maintained. The backspin controller 60monitors the bus voltage Vbus and detects when the bus voltage Vbusagain exceeds the threshold value, indicative of restoration of power,and the state machine transfers back to the normal RUN mode, allowingthe pump 32 to be restarted.

More specifically, with reference to FIG. 3, the start or RUN state 70represents the normal RUN condition in which the pump is operating. Whena power outage is detected, as indicated by detection that the busvoltage Vbus on the voltage bus 44 has decreased below a set point value(Vbus<Backspin_Bus_Min), this indicates that the voltage being suppliedby the utility to energize the voltage bus 44 is decreasing. For thiscondition, when Vbus<Backspin_Bus_Min, a velocity regulator is disabledand a negative torque is commanded, as indicated by reference number 91in FIG. 5, line A. The state machine transitions from the normal RUNmode to a forward REGENERATIVE mode or a BACKSPIN DECELERATION state 72.

Upon transitioning to the BACKSPIN DECELERATION state 72, the backspincontroller 60 commands a deceleration torque to provide controlleddeceleration of the motor (FIG. 5, line C). As the initial run velocityis positive and the motor drive torque is negative, the driveimmediately enters a forward regenerative condition, which maintains theDC bus voltage FIG. 5, line B and causes the motor and pump todecelerate from the positive run velocity (reference number 93 in FIG.5, line C). The negative torque command is maintained, allowing themotor and pump to decelerate through zero velocity (FIG. 5, line C) andinto a reverse direction. It is pointed out that the condition ofreversal of rotation of the pump combined with the negative torqueresults in a brief period wherein energy is drawn from the DC voltagebus, lowering its value (FIG. 5, line B). However, this transition isover quickly and the backspin controller maintains control and thenswitches to a BACKSPIN BUS VOLTAGE REGULATION state 74. Alternatively,and depending upon the fluid being pumped, when the speed reaches zero,a zero torque can be commanded, allowing the load to reverse. When thepump velocity decreases below a setpoint value,Motor_Vel<Backspin_Rev_Vel, indicative of a reversal in the direction ofrotation of the pump, the state machine transitions to the BACKSPIN BUSVOLTAGE REGULATION state 74, which is a reverse regeneration. In theBACKSPIN BUS VOLTAGE REGULATION state 74, the motor velocity regulatorand the bus voltage regulator are enabled to control the reverseregeneration.

It is important that the Backspin_Rev_Vel speed be maintained at theproper value. If the speed is too low, the drive will trip onundervoltage before the backspin bus voltage regulator can increase thespeed. If the speed is too high, the drive will trip with an overvoltagefault before the bus voltage regulator can decrease the speed. In eithercase, control of backspin is lost. In accordance with the presentinvention, the setpoint value Backspin_Rev_Vel for backspin reversevelocity is set to a value that is neither too high nor too low when nodynamic brake controller is used. In accordance with the presentinvention, when the optional dynamic brake controller 57 (FIG. 2) isused, the setpoint value Backspin_Rev_Vel for the backspin reversevelocity is set high enough to prevent an undervoltage condition and thevoltage regulating function provided by the dynamic brake controller 57(FIG. 2) prevents overvoltage conditions. The dynamic brake controller57 allows the Backspin_Rev_Vel speed to be set high since the dynamicbrake controller 57 will prevent overvoltage faults. The voltageregulating function provided by the dynamic brake controller 57 makesthe Backspin_Rev_Vel speed less critical and makes the backspincontroller 60 more reliable. Once running reverse, the backspin busvoltage regulator of the backspin controller 60 can gradually reduce thereverse speed, allowing the dynamic brake controller 57 to turn off. Thedynamic brake controller 57 can operate independently of the backspincontroller 60 or can be enabled along with the backspin controller 60 inresponse to a power disturbance. In either case, the setpoint valueBackspin_Rev_Vel for the backspin reverse velocity can be set highenough to prevent undervoltage condition with the voltage regulatingfunction provided by the dynamic brake controller 57 preventingovervoltage conditions.

For an extended power outage, the fluid column will become depleted. Asthe fluid column decreases, the load torque decreases because potentialenergy will decrease. At some point, prior to the column becomingdepleted, the potential energy will be insufficient to overcome motorlosses and the regulator will shut off. However, because the fluidcolumn is substantially depleted, this presents a safe condition forstartup which can occur immediately upon restoration of power.

The BACKSPIN BUS VOLTAGE REGULATION state 74 provides regulation of thebus voltage Vbus during the power outage until restoration of electricalpower to the voltage bus 44 is detected. In one embodiment, the busvoltage is regulated at a value Vreg, where Vreg=0.9*Backspin_Bus_Min.

When the bus voltage Vbus increases (reference number 95 in FIG. 5, lineB) to exceed the threshold value Backspin_Bus_Min,(Vbus>Backspin_Bus_Min) the state machine transitions back to theinitial RUN state 70 and the pump accelerates to the positive runvelocity. Typical variable speed drive current, torque or accelerationrate limiters can be used to control the return to the normal operatingspeed. Alternatively, transitioning from the BACKSPIN BUS VOLTAGEREGULATION state to RUN state can be conditioned additionally upon theelapsed time from the loss of power. In such embodiment, the transitionfrom the BACKSPIN BUS VOLTAGE REGULATION state to RUN state can occuronly when Te>Time (a time duration setpoint) in addition to thecondition that Vbus>Backspin_Bus_Min. This alternative condition isshown in brackets in FIG. 3. This alternative condition affords thecontrol with a degree of immunity to brief power outage glitches bymaintaining backspin control mode for a minimum time duration.

Backspin Controller

Referring to FIG. 4, there is shown a block diagram of a backspincontroller 60 in accordance with the present invention that works inconjunction with the finite state machine illustrated in FIG. 3.

The backspin controller 60 includes a backspin bus regulator 80,implemented by a proportional integral (PI) component and a velocityregulator 82, implemented by a further PI component. A selector 84closes to connect the backspin deceleration torque reference Tdec to thetorque command output Tcom when the state equals the BACKSPINDECELERATION state 72 (FIG. 3). Otherwise, the output of component 82 isconnected. A selector 86 selects the velocity reference from the outputof component 80 when the state equals the BACKSPIN BUS VOLTAGEREGULATION state 74 (FIG. 3). Otherwise, the run velocity setpointRun_Vel is connected. The selectors 84 and 86 are controlled by theFinite State Machine (FIG. 3).

The operational inputs to the backspin controller 60 include the busvoltage Vbus and the velocity Motor_Vel. In addition, the backspincontroller 60 includes a plurality of inputs for setpoint values andgain conditions. These inputs include a setpointVreg=0.9*Backspin_Bus_Min. When operating in the BACKSPIN BUS REGULATIONState, the controller regulates at Vreg which is 90% ofBackspin_Bus_Min. Under normal power conditions, Vbus is 630 vdc in oneexample. With no utility power, the backspin controller would regulatethe bus at 540 vdc in the BACKSPIN BUS VOLTAGE REGULATION state 74 for aBackspin_Bus_Min setting of 600 vdc. Thus, power restoration is easilydetected by the voltage changes from 540 vdc to 630 vdc. A reversevelocity Backspin_Rev_Vel is used as the setpoint value to causetransition from the deceleration state to the bus voltage regulationstate. A further input, the backspin deceleration torque, Tdec, is thenegative torque command in response to detection of a power outagecondition.

When the bus voltage exceeds the 600 vdc setpoint (Backspin_Bus_Min) inone embodiment, this is indicative that the utility power has beenreapplied to the power input circuit of the pump control system.

An integral gain factor G1 (Backspin_Ki) is used in the bus voltageregulation state. A proportional gain factor G2 (Backspin_Kp) is used inthe bus voltage regulation state. Similar PI gain factors G3 and G4 areused in the velocity regulator.

FIG. 4 illustrates the conditions for the normal RUN state, withselector 86 applying run velocity command, Run_Vel, to the rate limiter92 and selector 84 extending the output of the velocity regulator 82 tothe output of the backspin controller 60 which is a torque command Tcomfor the motor drive. The rate limiter 92 limits the rate of change ofthe speed setpoint (or acceleration). In the normal RUN state, summingblock 90 combines the motor velocity Motor_Vel with the run velocitysetpoint Run_Vel. The output of the summing block 90 is applied to thevelocity regulator 82 which produces a torque command Tcom forapplication to the motor drive for maintaining the motor at the setpointvalue.

The bus voltage Vbus is combined with the bus voltage setpoint Vreg bysumming block 88, the output of which is applied to the bus voltageregulator 80. The Finite State Machine (FIG. 3) causes the selector 84to switch to the BACKSPIN DECELERATION state when a power outage isdetected. The selector 84 is operated to extend the backspindeceleration torque Tdec signal to the output of the backspin controller60. Otherwise, selector 84 connects to the output of the velocityregulator 82.

When operating in the BACKSPIN BUS VOLTAGE REGULATION state, a velocitycommand, that is the output of the bus regulator 80 is applied throughthe selector 86 and the rate limiter 92 to summing block 90. Otherwise,the run velocity setpoint is connected to the rate limiter 92, forexample, during the normal run mode.

Referring to FIG. 3, in operation, the start state represents the normalRUN condition in which the pump is operating, producing a fluid flow upthe tubing. In the event of a power outage, voltage on the voltage bus44 begins to decrease. When the threshold is reached(Vbus<Backspin_Bus_Min), the velocity regulator is disabled and thebackspin controller 60 commands deceleration torque, Tdec, causing thesystem to transition to the next state. Upon transitioning to the nextstate, the backspin controller 60 provides controlled operation of thepump.

With reference to FIGS. 2 and 4, briefly, the backspin controller 60monitors the bus voltage and whenever the bus voltage decreases below athreshold level, transfers operation from the normal RUN mode to aregenerative mode. While operating in the regenerative mode, thebackspin controller 60 is operated and provides controlled operation ofthe pump, terminating in a slow reverse velocity, allowing the pump tobe restarted when electrical power is restored.

Referring to FIGS. 3 and 4, in operation, the RUN state 70 representsthe normal RUN condition in which the pump is operating, producing afluid flow up the production tubing. Selectors 84 and 86 are in thepositions shown in FIG. 4. The bus voltage Vbus typically is about 630vdc. The velocity regulator 82 maintains the velocity of the pump at thesetpoint Run_Vel. The backspin controller 60 monitors the bus voltageVbus. Whenever the bus voltage decreases below the 600 vdc thresholdlevel, (Vbus<Backspin_Bus_Min), indicative of a power outage, thebackspin controller transfers operation from the normal run mode to aregenerative mode. When operating in a regenerative mode, the backspincontroller 60 uses stored energy from the system to maintain internalcontrol voltage on the system during the power failure. The motor drivepower is maintained by commanding the motor drive to be in a powerregenerative condition, using the potential and kinetic energy of themotor and fluid column above the pump as the energy source.

More specifically, when the bus voltage Vbus decreases below thesetpoint 600 vdc, selector 84 is operated to disconnect the velocityregulator 82 and apply a negative deceleration torque, Tdec. Upontransitioning to the BACKSPIN DECELERATION state 72, the backspincontroller 60 is maintained energized and provides controlleddeceleration of the motor.

The motor slows as the result of the negative torque provided in theBACKSPIN DECELERATION state 72. When the motor velocity decreases belowa negative velocity setpoint (Motor_Vel<Backspin_Rev_Vel), the statetransitions from the BACKSPIN DECELERATION state 72 to the BACKSPIN BUSVOLTAGE REGULATION state 74. The selector 84 is operated, disconnectingthe deceleration torque command Tdec and connecting the velocityregulator 82. In addition, selector 86 is operated connecting the PI busregulator 80. In the BACKSPIN BUS VOLTAGE REGULATION state 74, the busvoltage Vbus is compared with the setpoint Vreg, which is 540 vdc in theexample, via summing block 88 and the PI bus regulator 80. As is statedabove, alternatively, when the velocity reaches zero, the controller cancommand a zero torque, allowing the load torque to reverse rotationuntil the motor velocity Motor_Vel exceeds the value forBackspin_Rev_Vel, causing the transition to the BACKSPIN BUS VOLTAGEREGULATION state 74 (FIG. 3).

When the bus voltage Vbus subsequently increases to exceed the thresholdvalue, (Vbus>Backspin_Bus_Min), the system transitions from the BACKSPINBUS VOLTAGE REGULATION state 74 back to the initial RUN state 70.

Test Results

FIGS. 6, 7, 8 and 9 are waveforms obtained by a laboratory dynamometerexperiment illustrating the operation of a drive backspin controller 60for power outages at various operating conditions. FIGS. 6 and 7illustrate the conditions for a motor operating at 100% speed and 100%torque. The results shown in FIG. 7 were obtained using the dynamicbrake controller 57 (FIG. 2) which allows the speed Backspin_Rev_Vel tobe set high. FIG. 8 illustrates the condition for a motor operating at100% speed and 50% torque. FIG. 9 illustrates the condition for a motoroperating at 50% speed and 100% torque. In FIGS. 6, 7, 8 and 9, channel1 is rectified line voltage, where 0.6 divisions equals rated busvoltage, channel 2 is the motor velocity where 1.6 divisions equalsrated speed, channel 3 is motor torque where 1.6 divisions equals ratedtorque and channel 4 is motor current where 0.7 division is the peak ofthe motor rated current. Portions of the motor current would normallyappear as a wide black line in FIGS. 6, 7, 8 and 9 (as well as in FIGS.12-15 and 20-22) because the motor current is alternating. At ratedmotor electrical speed of 60 cycles per second and a chart speed of 5seconds per division, the alternations are so close together as toappear as a wide black line. To avoid excessive black, these areas havebeen whited out, showing only the upper and lower outlines of thewaveform. The width between the outlines is proportional to the motorcurrent magnitude.

Power Dip Controller

Brownout conditions are addressed by a power dip controller provided bythe present invention. FIG. 11 is a flow chart of the power dipcontroller 100 in accordance with the invention.

Normally a pump drive would trip if the line voltage is reduced suchthat the bus voltage falls below its under voltage trip point. Evenbefore the drive trips the motor 36 (FIG. 2) is being operated with lessthan the adequate voltage causing a loss of motor power and motorcurrent distortion due to the motor 36 being starved for voltage.

The power dip controller 100 addresses these problems to allow the motor36 (FIG. 2) to keep running, producing optimum power output underbrownout conditions. The power dip controller 100 does this by weakeningthe motor field current and flux as the bus voltage is reduced during avoltage sag condition. A conventional field weakening controller wouldweaken the field if rated motor speed is exceeded. In contrast, thepower dip controller 100 weakens the field if motor rated speed isexceeded or bus voltage is less than adequate for the speed at which themotor 36 is running.

The power dip controller 100 monitors the bus voltage and the motorspeed and calculates a field weakening ratio FWR that is used inreducing the motor field and flux whenever the rated speed is exceededor the bus voltage becomes less than adequate for the speed at which themotor 36 is running. The motor field current used is determined bydividing the normal motor field current by the FWR factor. Similarly,the requested flux is determined by dividing the normal flux by the FWRfactor. Data, such as the current bus voltage, the FWR factor, and otherdata used in calculations made by the power dip controller 100 can bestored in a data memory of the controller 50 (FIG. 2). The FWR factor isapproximately equal to one under normal operating conditions, with busvoltage equal to Vbus Nom. The FWR factor is inversely proportional tothe operating voltage, as will be shown, and accordingly the FWR factorwill increase in correspondence with a decrease in the operatingvoltage. The power dip controller 100 is operable to prevent the FWRfactor from becoming less than one.

The power dip controller 100 manages motor field current and motor fluxby changing the FWR factor. Managing field current indirectly managesmotor flux. For more precise control, a flux regulator is also usedNormal flux divided by FWR is the setpoint for the flux regulator.

The power dip controller 100 responds to changes in the bus voltage Vbusto adjust the motor speed as shown in FIGS. 12-15. The amount ofadjustment made in motor speed is dependent upon the current operatingconditions. For example, when the motor is operating at 100% speed and100% torque, a 50% reduction in line voltage will result in a 50%reduction in motor speed to maintain the necessary torque.

This is illustrated FIG. 10, which is a graph of bus voltage (vdc—on theleft side and Vrms—corresponding to 3-phase line voltage on the rightside) as a function of speed. The relationship between bus voltage andspeed is approximately linear. Accordingly, a 50% decrease in the busvoltage will result in approximately a 50% decrease in speed or torque.As shown in FIG. 10, at 100% speed, the bus voltage is 460 Vrms (620vdc). If the bus voltage drops to 230 Vrms (half the normal value of 460Vrms) 310 vdc at 100% speed, the power dip controller 100 will regulatethe motor speed to 50% of the current motor speed to maintain the 100%maximum torque. Similarly, if the bus voltage drops to 155 vdc, ¼ of thenormal value to 115 Vrms at 100% speed, the power dip controller 100will regulate the motor speed to 25% of the current motor speed tomaintain 100% maximum torque. However, when the motor is operating atless than 100% speed (or torque) for example, a lesser or no adjustmentmay be needed as will be shown.

Referring to the flow chart in FIG. 11, the process begins in decisionblock 108 which determines if the bus voltage is less than a variableVbus_Temp. Vbus is the current bus voltage. Vbus_Temp is variable thatis stored to be used in a subsequent calculation. Nominal bus voltage isthe bus voltage that is expected at rated incoming voltage. For example,for a 460 VAC rated incoming voltage, the nominal bus voltage Vbus_Nomis given by:Vbus_Nom=460*1.35=621vdc,  (1)where 1.35 is the factor for a three-phase full wave rectifier feeding aDC bus through a link choke.

If the bus voltage is not less than Vbus_Temp, flow proceeds to block110 which sets a variable Vbus_Temp equal to Vbus_Temp+Vbus_Accel_Gain.The value Vbus_Accel_Gain is a gain set that is used to bring down theFWR ratio slowly for smoother response.

From block 110, flow proceeds to decision block 114 which determineswhether or not the bus voltage Vbus is less than Vbus_Temp. If the busvoltage is not less than Vbus_Temp, flow proceeds to block 117. If thebus voltage is not greater than Vbus_Temp, flow proceeds to block 116which sets Vbus_Temp equal to Vbus and flow then proceeds to block 117.

If decision block 108 determines that the bus voltage Vbus is less thanVbus_Temp, flow proceeds to block 112 which sets Vbus_Temp equal to Vbusand flow proceeds to decision block 117.

If decision block 117 determines that Vbus_Temp is greater thanVbus_Nom, then VBus_Temp is set equal to Vbus_Nom, block 119 and flowproceeds to block 118. If decision block 117 determines that Vbus_Tempis not greater than Vbus_Nom, flow proceeds directly to block 118.

Block 118 calculates the current value for the FWR factor. The FWRfactor is calculated from the relationship:FWR=(Motor_Vel/Rated_Vel)*(Vbus_Nom/Vbus_Temp)  (2)

The process flow proceeds to block 120 which determines if the fieldweakening ratio FWR is less than 1. If the field weakening ratio FWR isnot less than 1, flow returns to block 108 and the process repeats. Ifthe field weakening ratio FWR is less than 1, flow proceeds to block 122which sets FWR equal to 1 before returning to block 108. If FWR is lessthan 1, then the power dip controller 100 would be trying to strengthenthe field, an undesirable condition. By way of example, the process canbe repeated at a rate of about 1000 times per second.

The power dip controller 100 assumes that the motor is an AC inductionmotor. Motor rated velocity is the speed on the motor name plate. Thisis the speed when rated frequency and voltage is applied to the motorunder full load. For a 4-pole motor rated at 60 Hz and 460 volts itwould be a number like 1780 rpm. To run above motor rated velocitywithout extra voltage requires the motor field current and flux to bereduced. To run the motor at motor rated velocity at low bus voltagealso requires the motor field current and motor flux to be reduced. Thisis the control provided by the power dip controller 100.

The flow chart in FIG. 11 shows that the power dip controller 100increases the field weakening ratio (FWR) instantly in response to areduction in bus voltage. The FWR ratio is recalculated at a rate ofabout 1000 times per second. The field weakening ratio FWR is decreasedslowly for smooth response when the incoming voltage is restored. If thefield weakening ratio FWR is increased the motor field and flux isreduced allowing the motor 36 to run at any speed without being starvedfor voltage. This allows the motor 36 to maintain speed even under aseverely low bus voltage as long as the motor current limit is notreached. If the motor current limit is reached the motor 36 will slowdown until the field is strengthened enough so that the torque producedby the motor 36 at motor current limit is equal to the load.

FIG. 12 illustrates waveforms obtained by a laboratory dynamometerexperiment of the power dip controller 100 for a progressing cavity pumpoperating under constant torque conditions. As shown in FIG. 12, for a50% brownout condition, indicated in channel 1 of FIG. 12, the motor 36slows down to 50% speed (channel 2) at 100% torque (channel 3).

The typical normal input voltage operating range of drives is +10% to−10% of rated voltage. However, the drives can actually operate fromvoltages of 50% to 115% of rated voltage under controlled circumstances.The power dip controller 100 can be used to modulate the PCP operationto achieve maximum possible continuous production for any given voltagewithin that range. Power dips of up to 50% cause the drive to select anoperating point that maximizes pump speed within the torque limit of thesystem.

For example, a PCP normally running at full speed and 75% torque loadwill still be able to continue without loss of production for voltagedips down to 75% of drive rated voltage. At a dip of 50% of ratedvoltage the drive could produce full pump speed at half torque load,half pump speed at full torque load, or any other combination thatresults in a power draw that is 50% of drive rated power. Transientpower outages of fractions of a second will be able to briefly continuefull power operation using energy stored in the drive system.

FIGS. 12-17 illustrate waveforms obtained by a laboratory dynamometerexperiment of the power dip controller 100 for a progressing cavity pumpoperating under various speed and torque conditions. FIGS. 12-17 showthe operation of the drive power dip controller for a momentary voltagesags of 50% at various pump operating conditions. Channel 1 is rectifiedline voltage (where 0.6 division equals rated voltage), channel 2 is themotor velocity (where 1.6 division equals rated speed), channel 3 ismotor torque where 1.6 divisions equals rated torque, and channel 4 ismotor current (where 0.7 division is the peak of motor rated current).

Referring to FIG. 13, there are illustrated the conditions for a motoroperating at 100% speed and 100% torque. If the bus voltage is cut inhalf, the bus voltage Vbus becomes equal to Vbus_Nom/2, as indicated byreference number 124 in FIG. 13. For such condition, the FWR ratiobecomes equal to 2. The Vmotor constant (Kv) and the Torque constant(Kt) drop in half.

Accordingly, the drive tries to produce 100% torque which now requires200% current. The drive limits the current to 100%, cutting the torqueto 50%, as indicated by reference number 125 in FIG. 13. Even if thecurrent is not limited to 100%, the torque is reduced since the busvoltage is inadequate. The 50% available torque is less than the loadcausing the speed to fall. Consequently, the power dip controller 100decreases the motor speed to 50%, as indicated by reference number 126in FIG. 13. This allows torque to be increased until it again is at thenecessary torque value, as indicated by reference number 127 in FIG. 13.This is an iterative process, adjusting the motor speed to maintain thenecessary torque value. When the bus voltage is restored at Vnom, asindicated by reference number 128 in FIG. 13, allowing the speed to beincreased, as indicated by reference number 129 in FIG. 13.

FIG. 14 illustrates the conditions for a motor operating at 100% speedand 50% torque. If the bus voltage is cut in half, the bus voltage Vbusbecomes equal to Vbus_Nom/2, as indicated by reference number 129 inFIG. 13. However, aside from a slight disturbance due to the drop in busvoltage, the speed and torque are both are maintained at theirrespective operating levels. A similar operation results for a motoroperating at 50% speed and 100% torque, as shown in FIG. 15. FIG. 16illustrates the conditions for a 50% decrease in bus voltage for a motoroperating at 100% speed and 75% torque. FIG. 16. illustrates theconditions for a 50% decrease in bus voltage for a motor operating at75% speed and 100% torque. In both cases, the power dip controller 100maintains the torque at 75%, but the motor speed is decreased by about25% for the duration of the power disturbance.

Line regenerative drives use an active front end to convert the incomingAC line voltage into a regulated DC bus voltage. This conversion processcan be used to boost sagging input voltages to that required to operatethe motor at full speed. The power sag capability of line regenerativedrives is similar to that of the power dip controller 140 except thatoperation can be sustained to lower input voltages. The actual power dipthat can be tolerated will depend on the required pump power. Partiallyloaded PCPs could be operated at full speed from very low line voltagesprovided the input current rating of the drive is not exceeded.

Phase Loss Controller

Referring to FIGS. 2 and 19, phase loss and voltage imbalance conditionsare addressed by the phase loss controller 140 provided by the presentinvention. A 3-phase power source can become a single phase power sourceif one of the wires breaks, or if a fuse blows, interrupting one of the3-phase current paths. This complete loss of a phase can be consideredthe most extreme type of voltage imbalance. Normally, a pump drive wouldtrip if the incoming three phase voltage is reduced to single phase orthere is significant voltage imbalance. For 3-phase balanced supplyvoltage, bus voltage ripple is relatively low. Bus voltage rippleincreases significantly for single phase or imbalanced power as comparedwith balanced 3-phase power. Single phase or imbalanced incoming powercan overload the incoming voltage rectifier bridge 45 (FIG. 2) andsubject the bus capacitors 47 to excessive ripple current. In known ACpower conversion systems, the drive is disabled to prevent thecapacitors or rectifier bridge from failing, resulting in shut down ofthe drive under phase loss or voltage imbalance conditions. The phaseloss controller 140 of the present invention allows the pump 32 to keeprunning under phase loss and voltage imbalance conditions by reducingthe motor power output if required to keep the input rectifier andcapacitor ripple currents at or below their rated capacities.

The loss of an incoming phase or significant supply voltage imbalancewill normally disable conventional drives. The drives, according to thepresent invention, have the capability of detecting phase loss orvoltage imbalance but continuing operation at reduced capacity. Thephase loss controller can be used to modulate the PCP operation toachieve maximum possible production consistent with the drive singlephase or voltage imbalance capacity. These types of power disturbancecause the drive to select an operating point that maximizes pump speedwithin the torque limit of the system.

The phase loss controller 140 monitors bus ripple voltage. This voltagerepresents an increase in unbalanced rectifier and bus ripple current Aripple voltage of approximately 20% of the nominal DC bus voltage willbe the upper limit of what can be tolerated by typical variable speeddrive input rectifier and bus capacitors. The general concept of thephase loss controller is to use the magnitude of the bus ripple voltageto reduce the power demand of the drive to an acceptable level.

For example, a PCP normally running at full speed and 40% torque loadwill still be able to continue without loss of production in spite ofthe loss of one of its incoming phases. During single phase operation,the drive can produce full pump speed at 40% torque load, 40% pump speedat full torque load, or any other combination that results in a powerdraw that is 40% of drive rated power. The reduction in drive capacitydue to voltage imbalance is proportionate to the magnitude of thatimbalance. During a voltage imbalance condition, the drive willautomatically adjust to maximize production with the available capacity.

Referring to FIG. 19, the phase loss controller 140 reduces thehorsepower output of the drive if drive single phase or voltageimbalance capacity is exceeded, allowing the motor 36 to produce at mostthe power that results in rated capacities.

The phase loss controller 140 includes a proportional integral function(PI) 142, 144 and 148 that responds to a change in bus ripple currentwith respect to a setpoint value to adjust the output torque of thedrive if rated capacitor bus ripple current is exceeded. The outputtorque is reduced whenever the capacitor bus ripple current feedbackbecomes greater than the rated capacitor bus ripple current. The phaseloss controller 140 includes the torque output limiter 152, that limitsthe torque value to upper and lower limits.

Inputs to the phase loss controller 140 include the value of capacitorbus ripple current feedback Icap, the value of motor horsepower attorque limit, the current motor speed Motor_Vel, and a setpoint valuefor rated capacitor bus ripple current Irated. Motor rated velocityRated_Vel is the speed when rated frequency and voltage is applied tothe motor under full load. By way of example, for a 4-pole 460 voltmotor operating at 60 Hz, the speed would be 1780 rpm. Data, such as thevalue of capacitor bus ripple current, setpoint values, and other dataused in calculations made by the bus ripple controller 140 can be storedin the data memory 58 (FIG. 2). The output of the phase loss controller140 is the value calculated by the phase loss controller 140 for usedtorque limit. Bus ripple current is obtained by the relationship:

$\begin{matrix}{{Icap} = {C\frac{\left\lbrack {\mathbb{d}({Vbus})} \right\rbrack}{\mathbb{d}t}}} & (3)\end{matrix}$where C is the value of the bus capacitors 47 (and capacitors 48).

The capacitor bus ripple current feedback Icap is summed with thesetpoint value for rated capacitor bus ripple current Irated in summingblock 141. The result is multiplied by a proportional gain factor Kp inblock 142 and an integral gain factor Ki in block 144. The output ofblock 144 is integrated with respect to time by integrator 148. Theproportional and integral components obtained are summed with the valueof motor horsepower at torque limit in summing block 146. In block 150,the result is divided by the current motor speed, providing the torqueoutput at point 160 which is passed through the torque output limiter152, that limits the torque value to upper and lower limits, to theoutput 154 of the bus ripple controller 140.

The torque output limiter 152 limits the output of the bus ripplecontroller 140 to +torque and 0 limits. If the value at point 160exceeds the upper or lower torque limits, the output of the bus ripplecontroller 140 is clipped to the torque limits set by the torque outputlimiter 152. The integrator 148 is reset if the total horse power at 146exceeds motor horse power at torque limit*wind up factor (which, by wayof example, can have a value of about 1.2) or is less than zero. Thisprevents the integrator from winding up excessively. The integrator isreset to the value that results in motor horse power at torquelimit*wind up factor at 146 or zero depending on which is exceeded.Under normal conditions, the output of the bus ripple controller 140 istorque limit. Whenever the feedback ripple current exceeds the ratedcapacitor ripple current, the horsepower at summing point 146 isreduced. This lowered horsepower, divided by feedback speed Vel, reducesthe value of the torque limit output of the bus ripple controller 140.This, in turn, causes the motor 36 to slow down because the motor outputtorque now is less than the load torque which is substantially unchangedwith speed. As the motor 36 slows down, the used torque limit output ofthe bus ripple controller 140 increases. The motor speed stabilizes whenthe used torque limit becomes equal to the load torque and the busripple current equals the rated bus ripple current. The motor 36produces the maximum horsepower without exceeding the bus capacitorripple current limit. If the bus capacitor ripple current limit is notexceeded, the rectifier bridge 45 (FIG. 2) is protected because thehorsepower produced by the motor 36 is substantially reduced.

FIG. 18 is a graph of ripple current as a function of % power applied tothe motor. The offset ripple current is 3 amps. The drive ripple busdesign limit is 10 amps for 100% power. In FIG. 18, normal 3-phase busripple current as a function of power is shown by the solid line 130. Asshown, the current is 10 amp for 100% power.

In the event of a phase loss, the bus ripple current will increase. InFIG. 18, single phase bus ripple current as a function of power is shownby line 131 which includes a dashed portion 132, representing apotential increase in phase loss ripple current to about 25 amps.However, the phase loss controller 140 regulates to limit current to thedesign limit of 10 amps. However, this results in a reduction of about40% in power for a fixed torque, as shown in FIG. 18.

FIGS. 20-24 show the operation of the drive phase loss controller duringmomentary phase losses at various pump operating conditions. In FIGS.20-22, channel 1 is rectified line voltage (where 0.6 division equalsrated voltage), channel 2 is the motor velocity (where 1.6 divisionequals rated speed), channel 3 is motor torque (where 1.6 divisionsequals rated torque), and channel 4 is motor current (where 0.7 divisionis the peak of motor rated current).

Channel 1 of FIGS. 20-24 would normally appear as a wide dark line whenthe drive is running on a single phase. This is because the rectifiedsingle phase voltage is now 120 Hertz voltage (instead of 360 Hertzvoltage) with lower valleys between the voltage peaks which theoscilloscope follows up and down. To avoid excessive black, these areashave been whited out, showing only the upper and lower outlines of thewaveform. The bus voltage (not shown) drops slightly when running singlephase and has higher ripple. This results in higher ripple current inthe capacitors.

As is stated above, during single phase operation, the drive can producefull pump speed at 40% torque load, 40% pump speed at full torque load,or any other combination that results in a power draw that is 40% ofdrive rated power. The reduction in drive capacity due to voltageimbalance is proportionate to the magnitude of that imbalance. During avoltage imbalance condition, the drive will automatically adjust tomaximize production with the available capacity.

By way of example, FIG. 20 illustrates conditions for a motor operatingat 100% speed and 100% torque. If the bus ripple current increases dueto a phase imbalance or phase loss condition the motor power is reducedby reducing motor speed. In this example the input voltage switches tosingle phase at 133 in FIG. 20. This causes the ripple current to exceedthe rated ripple current. The ripple current controller thereforereduces the drive horse power at 146 of FIG. 19 to about 40%. Thiscauses the output of the ripple controller to drop to about 40% torque.The 40% available torque is less than the load causing the speed tofall. Consequently, the phase loss controller 140 decreases the motorspeed to 40%, as indicated by reference number 135 in FIG. 20. Thisallows torque to be increased until it again is at the necessary torquevalue, as indicated by reference number 136 in FIG. 20. This is aniterative process, adjusting motor speed to keep the ripple current atrated and the motor torque equal to the load torque. When the threephase bus voltage is restored, as indicated by reference number 137 inFIG. 20, the ripple current goes down allowing motor speed to go back to100%, as indicated by reference number 138 in FIG. 20.

FIG. 21 illustrates the conditions for a motor operating at 100% speedand 50% torque. At 139, the 3-phase incoming voltage is reduced tosingle phase. The ripple controller slows down the drive to about 80%speed to reduce the drive power output from 50% to 40% where the ripplecurrent feedback equals rated.

A similar operation results for a motor operating at 50% speed and 100%torque, as shown in FIG. 22. FIG. 23 illustrates the conditions forsingle phasing for a motor operating at 100% speed and 75% torque, inthis case the speed is reduced to 53% to maintain about 40% power. FIG.24 illustrates the conditions for single phasing for a motor operatingat 75% speed and 100% torque, in this case speed is reduced to 40% tomaintain about 40% power. In both cases, the power dip controllerreduces the power to 40% for the duration of the phase loss.

Several different strategies can be used to limit pump production lossdue to power disturbances. FIG. 25 provides a comparison of theproduction losses for a variety of conditions using the differentcontrol strategies. Those strategies can be divided into those thatloose and those that maintain control of the PCP during powerdisturbances. Loss of control of the PCP operation seriously jeopardizesproduction in wells with long backspin times. Pumps using backspin delaytimers can lose substantial production due to power disturbances of evenshort duration. The use of line regenerative drives or optionalcapacitor banks allow the PCP to ride through voltage dips of shortduration but not for power sags beyond a fraction of a second. The powerdip controller maintains PCP operation for voltage sags of up to 50% butnot for deeper sags in voltage. The phase loss controller can continueproduction indefinitely at reduced capacity during the loss in anincoming voltage phase or significant imbalance in the voltage source.The loss of phase or voltage imbalance will cause an alert that can beused to initiate an investigation into the cause of the power supplyproblem. By using the energy stored in the fluid column to maintain pumpoperation, the backspin controller eliminates virtually all lostproduction for power outages of even extended duration. The backspincontroller 60 eliminates virtually all lost production of power outageof any duration short of an extended blackout.

It may therefore be appreciated from the above detailed description ofthe preferred embodiment of the present invention that it provides asystem and method for driving a progressing cavity or electricalsubmersible pump that maintains the pump operating during powerdisturbances by using the regenerated energy supplied by the fluid loadon the pump or by modulating pump operation to match available powercapacity. For blackout conditions, the system and method detect powerloss and maintain the pump motor 36 running by using the regeneratedenergy produced as the result of the fluid load on the pump. Whenoperating in a regenerative mode, the backspin controller 60 uses storedenergy from the system to maintain internal control voltage on thesystem during the power failure. The drive 37 is kept energized bycontrolling the motor 37 to be in a power regenerative condition, usingthe potential and kinetic energy of the fluid column above the pump asthe energy source. For brownout conditions, the power dip controller 100provides controlled operation of the motor, weakening the motor fieldcurrent and flux as the bus voltage decreases during the brownoutcondition. For phase loss or voltage imbalance conditions, the phaseloss controller 140 provides controlled operation of the motor, reducingpower output to maintain bus capacitor ripple current at or below thecapacitor's rated ripple current.

Although an exemplary embodiment of the present invention has been shownand described with reference to particular embodiments and applicationsthereof, it will be apparent to those having ordinary skill in the artthat a number of changes, modifications, or alterations to the inventionas described herein may be made, none of which depart from the spirit orscope of the present invention. All such changes, modifications, andalterations should therefore be seen as being within the scope of thepresent invention.

1. A method for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive; said method comprising the steps of: determining an occurrence of an electrical power disturbance; determining whether the power disturbance is a blackout condition, a brownout condition, a phase loss condition or a voltage imbalance condition; and using a backspin controller to provide controlled operation of the motor when a power outage condition is determined to be a blackout condition, using a power dip controller to provide controlled operation of the motor when the power outage condition is determined to be a brownout condition, and using a phase loss controller to provide controlled operation of the motor when the power outage condition is determined to be a phase loss or voltage imbalance condition.
 2. The method according to claim 1, wherein using the backspin controller to provide controlled operation of the motor in response to detection of a blackout condition includes operating the backspin controller in a REGENERATIVE mode to maintain the motor drive power during a portion of the blackout condition, using load on the pump to recover energy stored in a fluid column produced by the pump for maintaining the motor drive power at least during said portion of the blackout condition.
 3. The method according to claim 1, wherein using the backspin controller in response to detection of a blackout condition to provide controlled operation of the motor includes causing direction of rotation of a rod string of the pump to be reversed at a controlled speed determined by the backspin controller, thereby preventing free backspinning of the rod string during the blackout condition.
 4. The method according to claim 1, wherein using the backspin controller in response to detection of a blackout condition to provide controlled operation of the motor includes monitoring a bus voltage and, whenever the bus voltage decreases below a threshold level, transferring operation from a RUN mode to the REGENERATIVE mode in which the backspin controller provides controlled deceleration of the pump.
 5. The method according to claim 1, including establishing a setpoint for a backspin reverse velocity at a value that prevents the backspin controller from responding to an undervoltage condition, and using a dynamic brake controller to provide a voltage regulating function to prevent an overvoltage condition.
 6. The method according to claim 5, wherein the dynamic brake controller operates independently of the backspin controller or is enabled along with the backspin controller in response to a power disturbance.
 7. The method according to claim 1, wherein using the power dip controller to provide controlled operation of the motor during a brownout condition includes weakening the motor field current and motor flux as a bus voltage decreases during the brownout condition.
 8. The method according to claim 7, wherein using the power dip controller to provide controlled operation of the motor during a brownout condition includes monitoring the bus voltage and the motor speed, calculating a value for a field weakening ratio using values of bus voltage and motor speed, and using the field weakening ratio to reduce motor field current and motor flux to reduced values whenever the rated motor speed is exceeded or the bus voltage becomes less than adequate for the speed at which the motor is running.
 9. The method according to claim 8, wherein determining the reduced value of motor field current includes obtaining a quotient of a value of normal motor field current and the value of the field weakening ratio, and wherein determining the reduced value of motor flux includes obtaining the quotient of a value of normal motor flux and the value of the field weakening ratio.
 10. The method according to claim 1, wherein using the phase loss controller to provide controlled operation of the motor in response to detection of a phase loss or voltage imbalance condition includes reducing motor power output to maintain a drive power output at or below that for a single phase capacity or voltage imbalance power capacity during the phase loss or voltage imbalance condition.
 11. The method according to claim 10, wherein detection of a phase loss or voltage imbalance condition includes monitoring a bus ripple voltage to detect at least an increase in bus ripple current, and responding to a change in bus ripple current relative to a setpoint value for rated bus ripple current to adjust an output torque command provided by the motor drive whenever the setpoint value is exceeded, and reducing the output torque whenever the bus ripple current feedback exceeds the setpoint value.
 12. The method according to claim 10, wherein detection of a phase loss or voltage imbalance condition includes detecting a change in the bus ripple current relative to a rated value of the bus ripple current, and wherein the phase loss controller responds to a change in the bus ripple current relative to a rated value of the bus ripple current to adjust motor speed to maintain the bus ripple current at the rated value and to maintain motor torque equal to load torque.
 13. A method for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive; said method comprising the steps of: detecting an occurrence of an electrical power disturbance condition; determining when the electrical power disturbance condition is a blackout condition; and using a backspin controller to provide controlled operation of the motor when the electrical power disturbance condition is determined to be a blackout condition, including operating the backspin controller in a REGENERATIVE mode to maintain the motor drive power during a portion of the blackout condition using load on the pump to recover energy stored in a fluid column produced by the pump to maintain the motor drive power at least during said portion of the blackout condition.
 14. The method according to claim 13, wherein the step of using the backspin controller to provide controlled operation of the motor includes the step of causing a direction of rotation of a rod string of the pump to be reversed at a controlled speed determined by the backspin controller, thereby preventing free backspinning of the rod string during the blackout condition.
 15. The method according to claim 13, wherein the step of using the backspin controller to provide controlled operation of the motor includes the steps of monitoring a bus voltage and, whenever the bus voltage decreases below a threshold level, transferring operation from a RUN mode to the REGENERATIVE mode in which the backspin controller provides controlled deceleration of the pump.
 16. The method according to claim 15, wherein the step of using the backspin controller to provide controlled operation of the motor includes responding to a parameter signal indicative that the motor speed has decreased to zero, to transfer operation of the backspin controller from the REGENERATIVE mode to a VOLTAGE REGULATION mode in which the backspin controller regulates the bus voltage to a setpoint value.
 17. The method according to claim 13, and including the steps of establishing a setpoint for a backspin reverse velocity at a value that prevents the backspin controller from responding to an undervoltage condition, and using a dynamic brake controller to provide a voltage regulating function to prevent an overvoltage condition.
 18. The method according to claim 17, wherein the dynamic brake controller operates independently of the backspin controller or is enabled along with the backspin controller in response to a power disturbance.
 19. A method for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive energized by a voltage derived from a bus voltage; said method comprising the steps of: monitoring the bus voltage; detecting an occurrence of an electrical power disturbance by determining when the amplitude of the bus voltage decreases below a setpoint value, indicative of a blackout condition; and providing controlled operation of the motor under the blackout condition to maintain the motor drive power during a portion of the blackout condition, including using a load on the pump to recover energy stored in a fluid column produced by the pump.
 20. The method according to claim 19, wherein the step of providing controlled operation of the motor under the blackout condition, includes the steps of operating a backspin controller in a REGENERATIVE mode, and using recovered energy to maintain the motor drive power at least during said portion of the blackout condition.
 21. The method according to claim 19, wherein the step of providing controlled operation of the motor under the blackout condition, includes the step of using a backspin controller to prevent free backspinning of a rod string of the pump during the blackout condition.
 22. The method according to claim 21, wherein the step of using the backspin controller to prevent free backspinning of the rod string during the blackout condition includes the step of causing the direction of rotation of the rod string of the pump to be reversed at a controlled speed determined by the backspin controller.
 23. The method according to claim 22, wherein the step of providing controlled operation of the motor under the blackout condition includes the step of transferring operation of the backspin controller from a RUN mode to the REGENERATIVE mode in which the backspin controller provides controlled deceleration of the pump.
 24. The method according to claim 23, wherein the step of providing controlled operation of the motor includes responding to a parameter signal indicative that the motor speed has decreased to zero, to transfer operation of the backspin controller from the REGENERATIVE mode to a VOLTAGE REGULATION mode in which the backspin controller regulates the bus voltage to a setpoint value.
 25. The method according to claim 21, including the steps of establishing a setpoint for a backspin reverse velocity at a value that prevents the backspin controller from producing an undervoltage condition, and using a dynamic brake controller to provide a voltage regulating function to prevent an overvoltage condition.
 26. The method according to claim 25, wherein the dynamic brake controller operates independently of the backspin controller or is enabled along with the backspin controller in response to a power disturbance.
 27. A system for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive; said system comprising: a voltage monitor for providing an output signal indicative of the amplitude of a bus voltage; a plurality of parameter monitors for providing outputs indicative of at least one operating parameter of the motor; and a backspin controller operable in a RUN mode to cause the motor to be driven in a forward direction, providing normal operation of the pump, the backspin controller being responsive to an output signal provided by said voltage monitor, indicative of an electrical power outage condition, to operate in a REGENERATIVE mode in which the backspin controller provides controlled deceleration of the pump by commanding a negative torque to cause the motor to decelerate.
 28. The system according to claim 27, wherein the backspin controller is responsive to an output signal, indicative of restoration of electrical power, provided by the voltage monitor to transfer operation of the backspin controller back to the RUN mode.
 29. The system according to claim 27, wherein the pump includes a rod string, and wherein the backspin controller is operable in the REGENERATIVE mode to control the motor drive to cause the direction of rotation of the rod string to be reversed and to cause the rod string to be driven at a controlled speed under the control of the backspin controller, thereby preventing free backspin of the rod string during at least a portion of the electrical power outage condition.
 30. The system according to claim 27, wherein the backspin controller is responsive to a parameter signal derived from outputs provided by the parameter monitors, indicative that the motor speed has decreased to zero, to transfer operation of the backspin controller from the REGENERATIVE mode to a VOLTAGE REGULATION mode in which the backspin controller regulates the bus voltage to a setpoint value.
 31. The system according to claim 27, wherein a setpoint for backspin reverse velocity is set at a value that prevents the backspin controller from producing an undervoltage condition, and further including a dynamic brake controller for providing a voltage regulating function to prevent an overvoltage condition.
 32. The system according to claim 31, wherein the dynamic brake controller operates independently of the backspin controller or is enabled along with the backspin controller in response to an electrical power outage condition.
 33. The system according to claim 30, wherein the backspin controller includes a backspin bus regulator implemented by a proportional integral component for producing a velocity reference, and a velocity regulator implemented by a further proportional integral component for producing a torque command for the motor drive. 